Wuhan Grat Control Valve Co., Ltd.

Contexte de l'application Dans les processus de traitement thermique de l'industrie métallurgique, les fours de recuit continu sont des équipements essentiels pour la production de bandes d'acier laminées à froid de haute qualité. Une grande aciérie du Hubei avait besoin d'un contrôle précis du débit dans la conduite d'air de combustion de sa ligne de recuit continu.Sous des ajustements à haute fréquence, les méthodes de contrôle traditionnelles souffraient de faible précision, réponse lente et défaillances fréquentes, tandis que le robinet papillon de ventilation électrique GRAT a développé une solution de régulation d'air fiable et de haute précision. Conditions de fonctionnement Cette application pose de sérieux défis aux performances des vannes, avec les paramètres de fonctionnement spécifiques suivants : Application : Conduite d'alimentation en air de combustion pour four de recuit continu Produit : Robinet papillon de ventilation électrique à faible charge GRAT Milieu : Air préchauffé Température : 120 °C – 300 °C (sous réserve de fluctuations fréquentes) Pression nominale : PN10 Taille : DN200 Raccordement : À bride Signal de commande : Commande modulante, 4-20mA Environnement d'exploitation : Réglage d'atelier industriel, nécessitant un équipement avec un indice de protection élevé et une capacité de fonctionnement continu. Durée de vie : ≥ 5 ans Avantages et caractéristiques du produit Le robinet papillon de ventilation électrique GRAT est conçu pour les environnements difficiles des fours de recuit : Contrôle proportionnel précis : Comporte un actionneur haute performance avec une précision de positionnement allant jusqu'à ±0,5 %. Maintient les fluctuations de l'atmosphère du four à moins de ±2 °C. Excellente résistance aux hautes températures : Construit en acier inoxydable SUS304, conservant plus de 85 % de sa résistance à 300 °C. Une conception de disque profilée réduit le couple requis de 40 %, économisant de l'énergie et réduisant l'usure. Haute fiabilité et longue durée de vie : Protection intégrée contre les surcharges empêche les dommages dus au blocage. Atteint un taux de fuite d'étanchéité inférieur à 0,01 % pour un cyclage à haute fréquence à long terme. Installation et maintenance faciles : Raccordement à bride standard pour une installation rapide. La conception modulaire garantit que le MTTR est inférieur à 30 minutes pour les composants clés. Résultats de performance Depuis sa mise en service en juillet 2017, la vanne a donné des résultats exceptionnels : Précision de contrôle améliorée : La fluctuation du volume d'air de combustion a été réduite de ±15 % à moins de ±6 %. La différence de température de la zone du four a été abaissée à moins de ±5 °C. Fiabilité prouvée : La vanne a fonctionné en continu sans défaillance pendant plus de 70 mois, accumulant plus de 250 000 cycles. Avantages économiques tangibles : Le taux de rendement du produit a augmenté de 92 % à 96,5 %, tout en réduisant simultanément le coût de fonctionnement par vanne. Durabilité exceptionnelle : Après avoir fonctionné 40 % au-delà de sa durée de vie prévue, la vanne reste en excellent état, offrant un retour sur investissement total de plus de 150 %. Le robinet papillon de ventilation électrique à faible charge GRAT démontre une adaptabilité et une fiabilité robustes dans les applications de contrôle de processus à haute température et à forte demande au sein de l'industrie métallurgique. Pour une solution de robinet papillon de ventilation électrique qui garantit efficacité et durabilité, GRAT est votre partenaire de confiance pour les nouveaux projets et les mises à niveau d'équipement.

Application Background In the heat treatment processes of the metallurgical industry, continuous annealing furnaces are core equipment for producing high-quality cold-rolled steel strips. A large steel plant in Hubei needed precise flow control in the combustion air pipeline of its continuous annealing line. Under high-frequency adjustments, Traditional control methods suffered from low precision, slow response, and frequent failures, while GRAT Electric Ventilation Butterfly Valve developed a high-precision, reliable air regulation solution. Operating Conditions This application poses severe challenges to valve performance, with specific operating parameters as follows: Application: Combustion air supply pipeline for continuous annealing furnace Product: GRAT Low-Load Electric Ventilation Butterfly Valve Medium: Preheated Air Temperature: 120°C – 300°C (subject to frequent fluctuations) Nominal Pressure: PN10 Size: DN200 Connection: Flanged Control Signal: Modulating Control, 4-20mA Operating Environment: Industrial workshop setting, requiring equipment with a high protection rating and continuous operation capability. Design Life: ≥ 5 years Product Advantages & Features The GRAT Electric Ventilation Butterfly Valve is engineered for the harsh environments of annealing furnaces: Precise Proportional Control: Features a high-performance actuator with positioning accuracy up to ±0.5%. Maintains furnace atmosphere fluctuations within ±2°C. Excellent High-Temperature Resistance: Constructed from SUS304 stainless steel, retaining over 85% of its strength at 300°C. A streamlined disc design reduces required torque by 40%, saving energy and reducing wear. High Reliability & Long Service Life: Built-in overload protection prevents damage from jamming. Achieves a seal leakage rate below 0.01% for long-term, high-frequency cycling. Easy Installation & Maintenance: Standard flanged connection for quick installation. Modular design ensures MTTR is less than 30 minutes for key components. Performance Results Since commissioning in July 2017, the valve has delivered exceptional results: Improved Control Accuracy: Combustion air volume fluctuation was reduced from ±15% to within ±6%. Furnace zone temperature difference was lowered to within ±5°C. Proven Reliability: The valve has operated continuously without failure for over 70 months, accumulating over 250,000 cycles. Tangible Economic Benefits: Product yield rate increased from 92% to 96.5%, while simultaneously reducing the operating cost per valve. Exceptional Durability: After operating 40% beyond its design life, the valve remains in excellent condition, delivering a total ROI by over 150%. Conclusion: The GRAT Low-Load Electric Ventilation Butterfly Valve demonstrates robust adaptability and reliability in high-temperature, high-demand process control applications within the metallurgical industry. For an Electric Ventilation Butterfly Valve solution that guarantees efficiency and durability, GRAT is your trusted partner for both new projects and equipment upgrades.

Valve Installation direction – a seemingly simple detail that directly impacts sealing performance and service life – is often overlooked in industrial pipeline and equipment maintenance. Especially when space is tight, a common question arises: “If it doesn’t fit vertically, can it be installed horizontally, or even upside down?” The answer isn’t universal; it depends entirely on the valve type and its internal design. Valves That MUST Be Installed in a Specific Direction First, let’s discuss valves that require strict adherence to installation direction, such as solenoid valves and pneumatic diaphragm valves. Incorrect Valve Installation for these types can lead to malfunction or rapid failure. For instance, a common pilot-operated solenoid valve relies on the media pressure differential to drive the valve core. If installed backwards, pressure can block the core, preventing it from opening even when energized. Even if it manages to open, the seal will wear out prematurely due to uneven force. Similarly, an upside-down Valve Installation for a pneumatic diaphragm valve puts constant stress on the diaphragm from gravity, leading to deformation, folding, reduced sealing precision, and a significantly shorter lifespan. Therefore, for these valves, you must follow the media flow direction indicated by the arrow on the valve body; never compromise due to space constraints. Valves with Flexible Installation Directions One category is electric valves – like electric ball valves and electric butterfly valves. These generally allow 360-degree installation in any orientation. Why such flexibility? The key lies in their design: their actuator typically uses a motor with gear transmission, which is unaffected by gravity. Regardless of orientation, power transmission efficiency remains above 95%. Sealing often involves O-rings combined with metal sealing surfaces, where the sealing pressure is controlled by bolt preload and is independent of the installation angle. Therefore, if vertical space is limited, an electric ball valve can be installed horizontally or even inverted in a ceiling plenum without compromising performance, making its Valve Installation highly adaptable. Another common category is pneumatic valves, such as pneumatic ball valves and pneumatic gate valves. They generally permit horizontal installation, but one critical point demands attention – the position of accessories, particularly the filter regulator. This component filters moisture and impurities from the compressed air and regulates pressure. Its bottom usually has a drain port. During Valve Installation, this drain port must face downwards. If it faces up or sideways, condensate cannot drain, accumulating inside the valve body. This leads to air pressure fluctuations, sluggish valve operation, and, more severely, moisture entering the cylinder, causing piston rust and seizure. For a horizontal Valve Installation, adjust the accessory bracket to ensure the drain port is vertically downward, leaving at least 10 cm of space for drainage. Solution for Valve Installation in Tight Spaces Guidelines for Valve Installation Direction When Space is Limited Valve Type Horizontal/Upside-Down Installation Allowed? Core Requirements and Reasons Solenoid Valve Strictly Forbidden Must be installed strictly according to the arrow on the valve body. Reverse installation can prevent the valve core from opening or cause rapid seal wear. Pneumatic Diaphragm Valve Strictly Forbidden Must be installed vertically upright. Inverted installation causes the diaphragm to deform under constant gravity pull, leading to seal failure. Electric Valve Allowed Supports 360° installation in any orientation. Its gear drive and seal design are unaffected by gravity direction. Pneumatic Valve Conditionally Allowed The valve body can be installed horizontally, but you must ensure the filter regulator’s drain port is vertically downward to prevent water accumulation and subsequent failure. Finally, here are two practical tips for any Valve Installation project: First, confirm the valve type to determine if it has orientation restrictions. Second, check accessory requirements, like the orientation of the filter regulator on pneumatic valves. Never assume based on past experience, as this easily leads to operational failures. When facing installation space limitations, consider our newly launched IoT Mini Electric Valve – engineered for compact spaces and high-precision control. This electric actuator features an integrated, compact design, with a volume one-third smaller than comparable torque products, yet it delivers a powerful 50 NM of torque. It supports 360° installation in any orientation, perfectly solving the challenge of insufficient vertical installation space. It supports AC220V or DC24V input, consumes only 10W of power, and fits ball valves up to DN40. Equipped with PWM stepless speed regulation and 0.5% high-precision control, it operates smoothly and adjusts accurately. The built-in brushless motor, integrated OLED Chinese status display, support for various signal feedback, and Modbus communication make it the ideal choice for flexible Valve Installation and reliable control in industrial automation systems. Small size, strong performance, and unrestricted installation orientation – the IoT Mini opens up new possibilities for your space-constrained automation systems. Welcome to learn more about our product details and inquire for custom solutions.

In PTA production plants within the chemical industry, the long-term stable operation of high-temperature and high-pressure steam control valves is crucial for the safety and economy of the entire process system. A PTA plant experienced control valve stem leakage in its steam regulation system. This valve leakage issue resulted not only in energy waste but also posed a threat to production safety. This GRAT case study will systematically analyze the cause of this valve leakage failure and provide a solution, offering a reference for valve selection and maintenance in similar working conditions. Technical Specifications Application: High-Temperature Steam Regulation System, PTA Chemical PlantMedium: Superheated SteamBody Material: WCBConnection Type: FlangedActuator Type: PneumaticOperating Temperature: 385℃Operating Pressure: 4.3MPaCommissioning Date: December 2024Installation Location: Steam Main Line, PTA Plant After approximately six months of continuous operation, significant steam leakage was observed at the valve stem position of this control valve. The rate of valve leakage gradually increased over time, severely impacting production safety and environmental performance. Troubleshooting & Analysis Upon arrival, the GRAT technical support team disassembled the faulty control valve for inspection and identified the following issues: A severe leakage path was present in the stuffing box area. The original PTFE packing showed obvious signs of aging and hardening. Some packing rings were severely worn and had lost their elastic sealing capability. Root Cause Analysis:PTFE packing is prone to hardening and aging in high-temperature environments. Its sealing performance degrades significantly with large temperature fluctuations. The steam temperature in this application reached 385℃, far exceeding the normal service temperature limit for PTFE packing (around 200℃). This caused rapid packing failure, leading directly to the observed steam valve leakage. Key factors influencing potential valve leakage include: Loose gland bolts with insufficient preload (e.g., due to long-term vibration) Worn or scratched valve stem surface (e.g., from solid particles in the medium) Incorrect packing installation methods (e.g., packing ring cuts not staggered) Use of packing material unsuitable for the service conditions (e.g., standard packing in high-temperature applications) Solution & Implementation Based on the specific site conditions, our technical personnel developed a targeted solution to stop the valve leakage: Packing Material Replacement: All original PTFE packing was replaced with flexible graphite packing. This material offers a wide temperature range (-200℃ to +600℃), excellent self-lubrication, and superior thermal stability, making it ideal for preventing high-temperature valve leakage. Optimized Packing Structure: A combination of layered flexible graphite rings and intermediate reinforcing rings was used. This structure ensures reliable sealing performance while enhancing the overall strength of the packing set to combat valve leakage. Standardized Installation Procedure: The packing was installed layer by layer according to standard procedures, ensuring all ring cuts were staggered. A torque wrench was used to tighten the gland bolts evenly to the recommended torque. After replacing the packing and optimizing the installation process, the control valve resumed stable operation. Following 72 hours of continuous monitoring using a portable volatile organic compound detector at multiple points around the gland, the valve stem seal showed zero leakage.

In a burner system, the control valve acts as a precise “conductor,” managing fuel supply and directly impacting combustion efficiency and safety. How does one scientifically select the correct valve for different fuels like natural gas or fuel oil? Senior Engineer Mr. Mo, with over 30 years of hands-on experience, shares his core insights. This article systematically organizes his expertise to help you master burner valve selection. Universal Burner Valve Selection Guide: Master These Six Points for Success Whether the medium is natural gas or fuel oil, a successful burner valve selection process must comprehensively consider the following six core elements, which form the foundation for stable system operation: Valve Body Material & Corrosion Resistance: Select appropriate corrosion-resistant materials such as stainless steel or special alloys based on the operating environment and the corrosiveness of the medium itself, ensuring long-term valve durability. Electrical Protection & Explosion-Proof Rating: In flammable or explosive atmospheres, it is essential to choose valves with electrical components and overall design that comply with onsite explosion-proof standards, minimizing safety risks. Control Accuracy & Flow Characteristics: Choose valves with the appropriate control precision and flow characteristics to achieve accurate and stable air-fuel ratio control. Flow Capacity (Cv Value): The valve’s flow capacity under a specific pressure drop should be slightly greater than the burner’s actual maximum flow requirement, providing a safety margin and avoiding system bottlenecks. Actuation Type & Power Source: Select electric or pneumatic actuation based on site conditions. Electric valves offer precise control and easy wiring; pneumatic valves provide fast action and excellent explosion-proof performance. The required voltage or air supply pressure must be confirmed. Media Pressure & Temperature: The valve’s pressure rating and temperature tolerance must exceed the media’s actual working pressure and temperature, ensuring seal integrity and structural safety. Core Comparison: Natural Gas vs. Fuel Oil Burner Valve Selection While following universal principles, the specific burner valve selection focus must be adjusted for different fuel properties: Selection Factor Natural Gas Control Valve Fuel Oil Control Valve Media Properties Clean, dry, but leakage must be prevented May contain impurities, be viscous, or corrosive Primary Concern Sealing Performance and Response Speed Clog Resistance and Corrosion/Temperature Resistance Material & Sealing Emphasizes high sealing classes to prevent gas leakage Materials must be oil-resistant and corrosion-resistant; some tolerance for impurities is needed Pressure & Temperature Focus on inlet pressure stability Often faces higher operating temperatures and pressures Recommended Product High-sealing Electric Ball Valves, Control Butterfly Valves Electric V-Port Ball Valves (The V-notch shears media, reducing jamming risk) Focus Analysis: Why Electric Actuation is Preferred for Quick Opening Valves For fast shut-off functions at the burner front end, electric valves demonstrate significant advantages over traditional solenoid valves: Higher Reliability: Electric actuators provide high torque, ensuring stable opening and closing cycles that are less susceptible to misoperation from media pressure fluctuations or impurities. Superior Impurity Resistance: Particularly with electric ball valves, the rotational movement of the ball can effectively cut through or displace small particles, offering a degree of “self-cleaning” and avoiding the jamming issues common in direct-acting solenoid valve designs. More Flexible Control: They can receive standard signals from PLC or DCS systems, enabling more complex interlock control strategies. Therefore, for applications demanding high reliability and media adaptability, an electric quick opening valve is the ideal burner valve selection for rapid switching duties. Conclusion Correct burner valve selection is the first step towards efficient and safe burner operation. Our quick opening electric valves are designed for this purpose, featuring 3-second operation, a lifespan exceeding 100,000 cycles, and revolutionary one-step debugging technology. They are key to enhancing your system’s response and safety. To learn how this product can protect your project, please contact us. We specialize in industrial valves, offering a comprehensive product line covering all control and quick opening valve needs for burner systems. If you have specific burner valve selection challenges or project requirements, just contact us for a customized solution from our expert engineers!

With 18 years of deep expertise in industrial chiller units, GRAT guide vane motors have consistently partnered with leading manufacturers in the industry. Renowned for exceptional reliability, our products have earned global customer trust and become the core power component ensuring stable cooling performance. Having undergone over a decade of rigorous market validation, more than 200,000 GRAT guide vane motors have been deployed worldwide. Our motors offer broad compatibility, supporting all types of centrifugal chillers—including single-stage compression, double-stage compression, variable frequency, and magnetic levitation models. They continuously protect the unit’s “heart” (compressor), ensuring trouble-free operation and establishing a stable temperature safety line for industrial processes. Core Patent Technology DDS Switching Debugging: Based on independent patented technology, this feature allows non-specialists to perform rapid calibration, significantly shortening installation and maintenance cycles. PPD Positioning: Precisely compensates for errors and maintains millimeter-level positioning accuracy. Combined with high-quality imported potentiometers, it guarantees long-term operational stability. Protection in Complex Environments Robust Housing: Constructed from aluminum alloy die-casting with an IP68 protection rating. High-Quality Components: Utilizes imported servo units and resin-encapsulated circuit boards. Anti-Interference: Excellent resistance to electromagnetic interference, making it suitable for challenging industrial environments such as those with high humidity and strong radiation. 18 Years of Reputation: The Choice of Global Customers The GRAT guide vane motor is the preferred choice for many world-renowned manufacturers, including: Dunham-Bush (Central Air Conditioning) Johnson Controls Hitachi Ebara Hisense Hitachi Grundfos Pumps CNOOC, Sinopec, CNPC China Shipbuilding Industry Corporation With over 200,000 units deployed, our motors serve critical cooling applications across the electronics, chemical, and pharmaceutical industries worldwide. GRAT remains committed to continuous product optimization through technological innovation. We aim to provide even more stable and efficient guide vane drive solutions for industrial chiller units, partnering with customers to create a new future in refrigeration.

Application Background As an important inorganic chemical pigment, titanium dioxide is widely used in many industrial fields such as coatings, plastics, and papermaking. Its product performance imposes high requirements on the stability and control precision of the production process. In the sulfuric acid method for titanium dioxide production, key processes like acid digestion and hydrolysis place stringent demands on the corrosion resistance, sealing performance, and control accuracy of valves. The GRAT electric hard seal ball valve, with its excellent corrosion resistance and precise regulation capability, provides a reliable fluid control solution for titanium dioxide production. Operating Conditions Model: GRAT Hard Seal Ball Valve Application: Controlling the flow rate and temperature of sulfuric acid during the acid digestion reaction. Medium: Sulfuric Acid Size: DN50 Material: SUS304 Connection Type: Flanged Control Signal: 4-20mA Power Supply: AC220V Design Life: 6 Years Commissioning Date: March 2014 Location: Hubei, China Product Advantages & Features Precise Control, Enhanced EfficiencyOur hard seal ball valve integrates an electric actuation system, enabling remote control and seamless automation compatibility. Utilizing proprietary PPD positioning technology, it achieves ±0.1% positioning accuracy with an adjustable dead zone of 0.3%–3.0%, ensuring high-precision regulation of media flow in diverse industrial applications. Robust Construction, Long-Lasting PerformanceKey components, including the ball and valve seats, are manufactured from specially formulated hard alloys. These materials offer superior hardness and outstanding wear resistance, effectively withstanding erosion from solid particles and fibrous media. As a result, the hard seal ball valve guarantees over 100,000 cycles of trouble-free operation. High-Temperature and High-Pressure ReliabilityEngineered with specially selected materials and reinforced construction, the hard seal ball valve excels in demanding high-temperature and high-pressure environments. Its durable design ensures long-term stability and safe performance, making it a reliable choice for critical pipeline systems. Compact and Cost-Effective DesignThe hard seal ball valve features a space-saving, compact design that simplifies installation and reduces operational footprint. Suitable for a wide range of media—including water, steam, petroleum, and corrosive substances—this valve minimizes maintenance needs and significantly lowers total lifecycle costs. Performance Results Achieved zero failures and zero leakage after continuous operation for 6 years in sulfuric acid, accumulating over 100,000 cycles. Maintained control accuracy within ±0.5%, precisely regulating sulfuric acid flow and temperature in the acid digestion process, ensuring reaction efficiency exceeded 90%. Internal component wear was less than 0.1mm, withstanding erosion and scouring from solid particles (0.5-2mm diameter) in the sedimentation process. Provided stable gas flow control in the calcination process at 800°C high-temperature conditions, ensuring calcined product whiteness remained above 98%. Achieved precise control speed in the hydrolysis process, reducing maintenance costs by 80% and significantly improving production efficiency. The electric hard seal ball valve holds significant application value in the titanium dioxide industry, where its advantages meet the demands of complex working conditions. The special structural design for high-temperature conditions ensures reliable operation, while its anti-clogging and high-temperature protection features enhance service life and production efficiency. The stringent requirements for performance and selection within the titanium dioxide industry also drive continuous optimization of the hard seal ball valve.

.gtr-container-pqr789 { font-family: Verdana, Helvetica, "Times New Roman", Arial, sans-serif; color: #333; line-height: 1.6; padding: 16px; box-sizing: border-box; overflow-x: hidden; } @media (min-width: 768px) { .gtr-container-pqr789 { max-width: 960px; margin: 0 auto; padding: 24px; } } .gtr-container-pqr789 h2 { font-size: 18px; font-weight: bold; margin-top: 24px; margin-bottom: 16px; color: #0056b3; } .gtr-container-pqr789 p { font-size: 14px; margin-bottom: 16px; text-align: left !important; word-break: normal; overflow-wrap: normal; } .gtr-container-pqr789 img { height: auto; } .gtr-container-pqr789 blockquote { margin: 20px 0; padding: 10px 20px; border-left: 4px solid #007bff; color: #555; font-style: italic; background-color: transparent; } .gtr-container-pqr789 ul { margin: 16px 0; padding-left: 20px; } .gtr-container-pqr789 ul li { list-style: none !important; position: relative; margin-bottom: 8px; padding-left: 15px; } .gtr-container-pqr789 ul li::before { content: "•" !important; position: absolute !important; left: 0 !important; color: #007bff; font-weight: bold; font-size: 1.2em; line-height: 1; } .gtr-container-pqr789 ol { margin: 16px 0; padding-left: 25px; counter-reset: list-item; } .gtr-container-pqr789 ol li { list-style: none !important; position: relative; margin-bottom: 8px; padding-left: 20px; } .gtr-container-pqr789 ol li::before { content: counter(list-item) "." !important; position: absolute !important; left: 0 !important; color: #007bff; font-weight: bold; font-size: 1em; text-align: right; width: 18px; } .gtr-container-pqr789 strong { font-weight: bold; } Dans les systèmes de contrôle d'automatisation industrielle, le fonctionnement fiable des vannes à boule électriques est essentiel à la sécurité et à l'efficacité des processus. L'étude de cas suivante décrit un exemple récent de dépannage où une vanne à boule électrique installée sur un pipeline de gaz d'un parc industriel n'a pas réussi à s'ouvrir ou à se fermer après la fin du câblage. Grâce à une inspection systématique et à une analyse professionnelle, notre équipe a rapidement identifié la cause première et mis en œuvre une solution efficace. Nous partageons le processus ci-dessous à titre de référence pour l'industrie. Spécifications techniques Scénario d'application : Pipeline de gaz d'un parc industriel Objectif : Arrêt principal du pipeline de gaz Fluide : Gaz naturel Taille de la vanne : DN300 Matériau du corps : WCB Type de raccordement : À bride Signal de commande : Signal de commutation Alimentation électrique de fonctionnement : CA220V Durée de vie prévue : 6 ans Date de mise en service : Décembre 2024 Lieu d'installation : Shanghai Après avoir terminé le raccordement du câble entre la vanne à boule électrique et l'armoire de commande, les opérateurs ont constaté que la vanne ne s'ouvrait ni ne se fermait sur commande. Cette défaillance a désactivé la fonction de régulation du pipeline de gaz, ce qui a eu un impact direct sur l'alimentation normale en gaz des entreprises du parc. Dépannage et analyse L'équipe de support technique de GRAT est intervenue rapidement. L'inspection initiale a confirmé le câblage correct, suivi d'une mesure systématique des paramètres électriques : La tension réelle mesurée aux bornes de l'actionneur électrique n'était que de CA80V, ce qui est nettement inférieur à la valeur nominale de CA220V. Selon la formule de la puissance P = UI (la puissance de l'actionneur est de 1,2 kW), avec une puissance constante, une diminution de la tension entraîne une augmentation du courant. Le courant de fonctionnement mesuré a atteint 18A. Ce courant excessif a déclenché la protection contre les surintensités intégrée de l'armoire de commande, empêchant ainsi la vanne à boule électrique de fonctionner. Analyse des causes profondes :La forte chute de tension était principalement due à la longue distance de câble de 600 à 700 mètres entre la vanne à boule électrique et l'armoire de commande. Sur une si longue distance pour la transmission de l'énergie, la chute de tension importante rendait impossible la satisfaction de la tension requise pour le démarrage normal de l'actionneur. Les principaux facteurs affectant la chute de tension de la ligne comprennent : Matériau du conducteur (par exemple, le câble à âme en cuivre a une résistivité plus faible et une chute de tension plus faible) Longueur de la ligne (une longueur plus importante augmente la chute de tension) Section du conducteur (une section plus importante réduit la résistance et la chute de tension) Température ambiante (une température plus élevée augmente la résistance du conducteur) Cette situation met en évidence une considération de conception essentielle : la prévention d'une chute de tension excessive sur les installations de vannes à boule électriques, en particulier sur de longues distances. Solution et mise en œuvre Pour remédier à la cause première de la défaillance, nous avons évalué deux solutions possibles : Modifier la tension nominale : Modifier la tension de fonctionnement de l'actionneur de CA220V à CA380V. Bien que le CA380V offre une tension stable et un courant plus faible, cette option a été exclue en raison de l'absence d'une source d'alimentation CA380V sur site, des coûts élevés pour le remplacement de l'actionneur et des problèmes de compatibilité potentiels. Déplacer l'armoire de commande : Après discussion avec le personnel sur site, l'armoire de commande a été rapprochée de la vanne à boule et le câblage a été réinstallé. Les tests post-relocalisation ont confirmé que la vanne à boule a repris son fonctionnement normal, résolvant ainsi la défaillance. Résultats de la mise en œuvre :Après avoir opté pour la solution 2, notre équipe de construction a exécuté le plan rapidement. L'armoire de commande a été repositionnée à environ 50 mètres de la vanne à boule électrique. De nouveaux câbles d'alimentation et de commande ont été installés conformément aux spécifications. Le débogage et les tests post-modification comprenaient : Mesure de la tension à l'entrée de l'actionneur avec un voltmètre de précision, confirmant un CA215V stable, répondant pleinement aux exigences nominales. Vérification du courant de démarrage avec une pince ampèremétrique, indiquant une lecture stable de 8,2 A, dans la plage de fonctionnement normale. Réalisation de plusieurs tests d'ouverture/fermeture, la vanne à boule électrique répondant avec précision et fiabilité aux signaux de commande. Après 72 heures de surveillance continue, tous les paramètres du système sont restés stables, confirmant que la défaillance était complètement éliminée. Cette résolution réussie a non seulement résolu le problème immédiat, mais a également fourni des informations précieuses pour la planification de la disposition des actionneurs électriques dans des conditions similaires, servant de référence clé pour la conception de projets futurs. Résumé de l'expérience Cette étude de cas réitère que, lors des phases de conception et d'installation des systèmes d'automatisation industrielle, une évaluation complète des paramètres du système électrique et de la disposition des équipements est essentielle. Une attention particulière doit être accordée à : Évaluation précise des distances d'alimentation afin d'éviter un dysfonctionnement de l'équipement dû à la chute de tension de la ligne. Sélection scientifique des spécifications des câbles, en tenant compte de sections plus importantes pour les scénarios de transmission d'énergie sur de longues distances. S'assurer qu'une planification intégrée tient compte de la correspondance de l'alimentation, du placement de l'équipement et de la logique de commande. La gestion efficace de la chute de tension sur les systèmes de vannes à boule électriques est cruciale pour la fiabilité. GRAT reste déterminé à fournir des services techniques professionnels et une analyse rigoureuse des défaillances, en proposant des solutions de vannes de régulation fiables pour assurer la sécurité, la stabilité et l'efficacité des systèmes industriels. Nous accueillons les demandes de renseignements et la coopération de clients de divers secteurs.